WO1993006981A1 - A method of moulding a component and a component made by such a method - Google Patents

A method of moulding a component and a component made by such a method Download PDF

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Publication number
WO1993006981A1
WO1993006981A1 PCT/GB1992/001763 GB9201763W WO9306981A1 WO 1993006981 A1 WO1993006981 A1 WO 1993006981A1 GB 9201763 W GB9201763 W GB 9201763W WO 9306981 A1 WO9306981 A1 WO 9306981A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
sheet
paint
component
providing
Prior art date
Application number
PCT/GB1992/001763
Other languages
French (fr)
Inventor
Gordon Frederick Smith
Ronald Arthur Easterlow
Original Assignee
Rover Group Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rover Group Limited filed Critical Rover Group Limited
Priority to GB9402816A priority Critical patent/GB2274425B/en
Publication of WO1993006981A1 publication Critical patent/WO1993006981A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/20—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/18—Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2623/00—Use of polyalkenes or derivatives thereof for preformed parts, e.g. for inserts
    • B29K2623/10—Polymers of propylene
    • B29K2623/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars

Definitions

  • the invention relates to a method of moulding a component and to a component made by such a method.
  • the invention is primarily concerned with a method of producing a pre-painted component by moulding.
  • Various methods have been proposed hitherto of producing components which comprise a substrate of plastics material having a surface finish comprising a layer of paint.
  • One example of such a method is disclosed in WO88/07416 where a layer of paint is first applied to a thin film of material, solvents in the paint are allowed to evaporate, the layer is transferred to a thermofor able backing sheet which is subsequently preformed to a desired shape and the substrate is then bonded to the backing sheet by an injection moulding step or thermosetting moulding techniques.
  • Fibre reinforced thermoplastics sheeting for example, polypropylene filled glass mat sheet, can be used to form mechanically strong components but does not provide a particularly good surface finish due to shrinkage of the plastics from the fibre during cooling.
  • An object of the present invention is to provide a method of moulding which will enable a moulded component to be produced combining the rigid and hard wearing characteristics of such sheeting with an improved surface finish provided by a layer of paint.
  • a method of moulding a component comprising providing a layer of paint in a mould, providing a sheet of fibre reinforced thermoplastics material, heating the sheet, introducing the heated sheet into the mould and compressing the sheet to cause the material of the sheet to flow over a surface of the mould to form a component having a substrate formed by the material of the sheet and a finish provided by the layer of paint.
  • the thickness of the paint layer is selected to hide the effect of the relatively poor surface finish of the material of the sheet and the strength and durability characteristics of the sheet are retained with the paint layer providing a much improved surface finish.
  • One method in accordance with the invention includes providing the layer of paint on one side of a film of material.
  • the film provides a convenient carrier for the paint and, if desired, can be pre-formed so as to conform substantially with the shape of the mould or at least that part of the mould which receives the paint layer.
  • the material of the film is preferably of a kind which is compatible with the material of the sheet and the film is preferably arranged such that material of the sheet spreads over and bonds with the other side of the film, i.e. the opposite side to that carrying the layer of paint.
  • paint is applied directly to the mould to form a layer thereon.
  • the paint is applied directly to a suitable preform means corresponding substantially to the shape of at least part of the mould, i.e. that part normally intended to receive the paint layer.
  • the layer of paint is subsequently removed from the preform means whilst retaining its preformed shape.
  • the layer can then be transferred to the mould and positioned in the complementary shaped part thereof ready for the introduction of the heated sheet of fibre reinforced plastics material.
  • the paint layer may be applied to the mould or preform means by a technique known as slush moulding.
  • slush moulding a technique known as slush moulding.
  • the mould or preform means is heated and a layer of powdered plastics paint is applied thereto. Heat is then applied thereto with the layer of powdered paint thereon so that the powdered paint forms a fused layer.
  • the layer is removed from the preform means and positioned in the mould ready for the introduction of the heated sheet of the fibre reinforced material.
  • the sheet will be heated to a temperature sufficient to cause the layer of paint material, or at least the surface thereof which contacts the heated sheet, and the material of the sheet to bond together homogeneously.
  • the method may include providing a plurality of said sheets of fibre reinforced thermoplastics material, heating the plurality of sheets, introducing said plurality of sheets into the mould and compressing the sheets to cause the material of the sheets to flow over a surface of the mould and bond homogeneous1y together.
  • a component such as a motor vehicle body component, for example a body panel, comprising a substrate of plastics material having a coating of paint to provide a finish, the component being formed by providing a layer of the paint in a mould, providing a sheet of fibre reinforced plastics material, heating the sheet, introducing the heated sheet into the mould and compressing the sheet in the mould to cause the material of the sheet to flow over a surface of the mould to form the component.
  • Such a component as set out in the immediately preceding paragraph is produced by a method according to said one aspect of the invention or can be produced in accordance with any of the method steps set out in the consistory clause paragraphs relating thereto.
  • a method of moulding a component comprising providing a film of material having a coating of paint on one side, providing a sheet of fibre reinforced thermoplastics material, heating' the sheet and pressing the sheet against the other side of the film whereby the temperature of the sheet causes the film to bond therewith and form a component having a finish provided by the paint.
  • Fig.1 is a diagrammatic cross-section through a mould for use in a method in accordance with the invention shown with two parts of the mould separated,
  • Fig.2 is a diagrammatic cross-section of the mould shown in Fig.1 with the mould parts brought together to form the component
  • Fig.3 is a view drawn to a larger scale of part of a polypropylene filled glass mat sheet and a painted film which are bonded together when forming the componen ,
  • Fig.4 is a view of a component formed by the mould shown in Figs.1 and 2,
  • Figs.5 to 8 show diagrammatically applying paint to a preform tool by slush moulding
  • Fig.9 shows a mould part having the slush moulded paint layer therein.
  • a mould comprises first and second parts 10, 12.
  • the first part 10 is movable towards the second part 12 by a mechanism (not shown).
  • the first mould part 10 defines a projection 13 and the mould part 12 defines a complementary shaped recess or cavity 14.
  • a layer of film-like material 15 such as polypropylene film is provided with a coating of thermoplastics paint 16 as shown in Fig. .
  • the film 15 is preformed, e.g., by vacuum forming so as to conform substantially to the shape of the recess 14.
  • a sheet 17 is provided comprising thermoplastics material 17a and reinforcement fibres 17b (see Fig.3).
  • the sheet 17 is a polypropylene filled glass mat sheet (GMT) .
  • the method of moulding includes heating the sheet 17 by a heating device (not shown), placing the film 15 and heated sheet 17 between the mould parts 10, 12
  • the mould parts being cold or at least substantially cooler than the heated sheet 17 for example 80 C
  • the temperature of the mould parts can be controlled to provide the desired temperature.
  • the pressure of the mould causes the heated material of the sheet 17 to flow and spread outwardly over the surface of mould part 10 and over the surface of the film 15 as shown in Fig.2.
  • the temperature of the sheet 17 is sufficiently high to cause the polypropylene film 15 and the polypropylene material 17a of the sheet 17 to bond together homogeneously as by welding when the mould 10, 12 are urged together under pressure to compress the heated sheet.
  • the sheet 17 and painted film 15 bonded thereto are removed from the mould as a single component 18 having a finish provided by the layer of paint 16. Unwanted edge margins 15a of the film can then be removed.
  • the painted film 15 may be of a laminated kind comprising layers of plastics material such as polypropylene and a polyamide.
  • a film of that kind is described in our co-pending U.K. Patent Application No.9120618.5 and may have thickness in the range 0.15 mm to 1.00 mm.
  • the painted layer has thickness t in the range of 0.01 mm to 0.15 mm.
  • the combined paint and film hide the effect of the relatively poor surface of the GMT to provide a smooth paint finish.
  • a plurality of pre-heated sheets 17 could be positioned within the mould as shown in broken lines in Figs.1 and 2, and would be compressed together in the mould to produce a thick component having the sheets 17 bonded together homogeneously and having the painted film 15 bonded to the material of the adjacent sheet.
  • paint can be applied as a layer 16a to a pre-form tool 20 having a cavity 21 which is substantially the same shape and size as the cavity 14 defined by the mould part 12 shown in Fig.1.
  • the paint is a powdered plastics paint applied to the preform tool by a process known as slush moulding.
  • the preform tool 20 is initially heated in an oven 22. After heating, the tool is assembled as in Fig.6 over a container 23 having the desired powdered plastics paint 24 therein. The assembly is then inverted as in Fig.7 and a vacuum is preferably applied to the inside of the container. The inverted assembly is then preferably rotated so as to spread the powdered paint over the tool surface. The tool 20 is then separated from the container 23 with powdered paint adhering thereto. The tool is subsequently cooled, e.g., in a waterbath 25 as in Fig.14, and the set layer of paint indicated is removed for positioning in the mould cavity 14 as in Fig.9.
  • the paint may be selected from the EvoShield (Trade Mark) range of paints obtainable from Evode Group pic.
  • mould part 12 which would take the place of the preform tool 20 as shown in broken lines in Figs.5 to 8. After cooling, the mould part 12 with the paint layer 16a thereon is ready to receive the sheet or sheets 17.
  • the thickness t' of the paint layer 16a is in the range of 0.2 mm to 0.5 mm to hide the surface irregularities of the fibre reinforced material of the sheet or sheets 17.
  • the sheet 17 has been referred to as a polypropylene filled glass mat sheet but may comprise carbon fibre reinforcement and an alternative type of thermoplastics material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The method comprises providing a layer of paint (16) in a mould (10, 12), providing a sheet of fibre reinforced thermoplastics material (17), heating the sheet, introducing the heated sheet into the mould and compressing the sheet in the mould to cause the material of the sheet to flow over a surface of the mould. The method enables a component (18) to be formed having a substrate formed by the material of the sheet (17) and a finish provided by the paint (16).

Description

A METHOD OF MOULDING A COMPONENT
AND A COMPONENT MADE BY SUCH A METHOD
The invention relates to a method of moulding a component and to a component made by such a method.
The invention is primarily concerned with a method of producing a pre-painted component by moulding.
Various methods have been proposed hitherto of producing components which comprise a substrate of plastics material having a surface finish comprising a layer of paint. One example of such a method is disclosed in WO88/07416 where a layer of paint is first applied to a thin film of material, solvents in the paint are allowed to evaporate, the layer is transferred to a thermofor able backing sheet which is subsequently preformed to a desired shape and the substrate is then bonded to the backing sheet by an injection moulding step or thermosetting moulding techniques.
Fibre reinforced thermoplastics sheeting (GMT), for example, polypropylene filled glass mat sheet, can be used to form mechanically strong components but does not provide a particularly good surface finish due to shrinkage of the plastics from the fibre during cooling.
An object of the present invention is to provide a method of moulding which will enable a moulded component to be produced combining the rigid and hard wearing characteristics of such sheeting with an improved surface finish provided by a layer of paint.
According to one aspect of the invention there is provided a method of moulding a component comprising providing a layer of paint in a mould, providing a sheet of fibre reinforced thermoplastics material, heating the sheet, introducing the heated sheet into the mould and compressing the sheet to cause the material of the sheet to flow over a surface of the mould to form a component having a substrate formed by the material of the sheet and a finish provided by the layer of paint.
The thickness of the paint layer is selected to hide the effect of the relatively poor surface finish of the material of the sheet and the strength and durability characteristics of the sheet are retained with the paint layer providing a much improved surface finish.
One method in accordance with the invention includes providing the layer of paint on one side of a film of material.
The film provides a convenient carrier for the paint and, if desired, can be pre-formed so as to conform substantially with the shape of the mould or at least that part of the mould which receives the paint layer. The material of the film is preferably of a kind which is compatible with the material of the sheet and the film is preferably arranged such that material of the sheet spreads over and bonds with the other side of the film, i.e. the opposite side to that carrying the layer of paint.
In another method in accordance with the invention, paint is applied directly to the mould to form a layer thereon.
In a further method in accordance with the invention, the paint is applied directly to a suitable preform means corresponding substantially to the shape of at least part of the mould, i.e. that part normally intended to receive the paint layer. The layer of paint is subsequently removed from the preform means whilst retaining its preformed shape.
Once removed, the layer can then be transferred to the mould and positioned in the complementary shaped part thereof ready for the introduction of the heated sheet of fibre reinforced plastics material.
The paint layer may be applied to the mould or preform means by a technique known as slush moulding. In such a case the mould or preform means is heated and a layer of powdered plastics paint is applied thereto. Heat is then applied thereto with the layer of powdered paint thereon so that the powdered paint forms a fused layer. After cooling, the layer is removed from the preform means and positioned in the mould ready for the introduction of the heated sheet of the fibre reinforced material.
In the immediately preceding three methods, the sheet will be heated to a temperature sufficient to cause the layer of paint material, or at least the surface thereof which contacts the heated sheet, and the material of the sheet to bond together homogeneously.
The method may include providing a plurality of said sheets of fibre reinforced thermoplastics material, heating the plurality of sheets, introducing said plurality of sheets into the mould and compressing the sheets to cause the material of the sheets to flow over a surface of the mould and bond homogeneous1y together.
According to another aspect of the invention there is provided, a component, such as a motor vehicle body component, for example a body panel, comprising a substrate of plastics material having a coating of paint to provide a finish, the component being formed by providing a layer of the paint in a mould, providing a sheet of fibre reinforced plastics material, heating the sheet, introducing the heated sheet into the mould and compressing the sheet in the mould to cause the material of the sheet to flow over a surface of the mould to form the component.
Such a component as set out in the immediately preceding paragraph is produced by a method according to said one aspect of the invention or can be produced in accordance with any of the method steps set out in the consistory clause paragraphs relating thereto.
According to a further aspect of the invention there is provided a method of moulding a component comprising providing a film of material having a coating of paint on one side, providing a sheet of fibre reinforced thermoplastics material, heating' the sheet and pressing the sheet against the other side of the film whereby the temperature of the sheet causes the film to bond therewith and form a component having a finish provided by the paint.
Methods of moulding a component and components made by such methods in accordance with the invention will now be described by way of example with reference to the accompanying drawings in which:-
Fig.1 is a diagrammatic cross-section through a mould for use in a method in accordance with the invention shown with two parts of the mould separated,
Fig.2 is a diagrammatic cross-section of the mould shown in Fig.1 with the mould parts brought together to form the component,
Fig.3 is a view drawn to a larger scale of part of a polypropylene filled glass mat sheet and a painted film which are bonded together when forming the componen ,
Fig.4 is a view of a component formed by the mould shown in Figs.1 and 2,
Figs.5 to 8 show diagrammatically applying paint to a preform tool by slush moulding, and
Fig.9 shows a mould part having the slush moulded paint layer therein.
In Fig.1 a mould comprises first and second parts 10, 12. In the embodiment illustrated, the first part 10 is movable towards the second part 12 by a mechanism (not shown). The first mould part 10 defines a projection 13 and the mould part 12 defines a complementary shaped recess or cavity 14.
A layer of film-like material 15 such as polypropylene film is provided with a coating of thermoplastics paint 16 as shown in Fig. . The film 15 is preformed, e.g., by vacuum forming so as to conform substantially to the shape of the recess 14. A sheet 17 is provided comprising thermoplastics material 17a and reinforcement fibres 17b (see Fig.3).
Preferably, the sheet 17 is a polypropylene filled glass mat sheet (GMT) .
The method of moulding includes heating the sheet 17 by a heating device (not shown), placing the film 15 and heated sheet 17 between the mould parts 10, 12
(the mould parts being cold or at least substantially cooler than the heated sheet 17 for example 80 C) and bringing the mould parts together as shown in Fig.2 to compress the heated sheet 17. The temperature of the mould parts can be controlled to provide the desired temperature. The pressure of the mould causes the heated material of the sheet 17 to flow and spread outwardly over the surface of mould part 10 and over the surface of the film 15 as shown in Fig.2. The temperature of the sheet 17 is sufficiently high to cause the polypropylene film 15 and the polypropylene material 17a of the sheet 17 to bond together homogeneously as by welding when the mould 10, 12 are urged together under pressure to compress the heated sheet. After moulding, the sheet 17 and painted film 15 bonded thereto are removed from the mould as a single component 18 having a finish provided by the layer of paint 16. Unwanted edge margins 15a of the film can then be removed.
The painted film 15 may be of a laminated kind comprising layers of plastics material such as polypropylene and a polyamide. A film of that kind is described in our co-pending U.K. Patent Application No.9120618.5 and may have thickness in the range 0.15 mm to 1.00 mm. The painted layer has thickness t in the range of 0.01 mm to 0.15 mm. The combined paint and film hide the effect of the relatively poor surface of the GMT to provide a smooth paint finish.
If desired, a plurality of pre-heated sheets 17 could be positioned within the mould as shown in broken lines in Figs.1 and 2, and would be compressed together in the mould to produce a thick component having the sheets 17 bonded together homogeneously and having the painted film 15 bonded to the material of the adjacent sheet. As shown in Figs.5 to 8, paint can be applied as a layer 16a to a pre-form tool 20 having a cavity 21 which is substantially the same shape and size as the cavity 14 defined by the mould part 12 shown in Fig.1. The paint is a powdered plastics paint applied to the preform tool by a process known as slush moulding.
The preform tool 20 is initially heated in an oven 22. After heating, the tool is assembled as in Fig.6 over a container 23 having the desired powdered plastics paint 24 therein. The assembly is then inverted as in Fig.7 and a vacuum is preferably applied to the inside of the container. The inverted assembly is then preferably rotated so as to spread the powdered paint over the tool surface. The tool 20 is then separated from the container 23 with powdered paint adhering thereto. The tool is subsequently cooled, e.g., in a waterbath 25 as in Fig.14, and the set layer of paint indicated is removed for positioning in the mould cavity 14 as in Fig.9. The paint may be selected from the EvoShield (Trade Mark) range of paints obtainable from Evode Group pic.
Instead of slush moulding the paint 16a on to the preform tool 20, it could be slush moulded directly on to the mould, e.g. mould part 12 which would take the place of the preform tool 20 as shown in broken lines in Figs.5 to 8. After cooling, the mould part 12 with the paint layer 16a thereon is ready to receive the sheet or sheets 17.
The thickness t' of the paint layer 16a is in the range of 0.2 mm to 0.5 mm to hide the surface irregularities of the fibre reinforced material of the sheet or sheets 17.
The sheet 17 has been referred to as a polypropylene filled glass mat sheet but may comprise carbon fibre reinforcement and an alternative type of thermoplastics material.

Claims

1. A method of moulding a component comprising providing a layer of paint (16 16a) in a mould (10, 12) and introducing a thermopl stics material (17) into the mould to form a component (18) having a substrate formed by the material (17) and a finish provided by the paint (16, 16a), characterised by providing the thermoplastics material as a sheet of reinforced thermoplastics material (17), heating the sheet, introducing the heated sheet into the mould (10, 12) and compressing the sheet in the mould to cause the material of the sheet to flow over a surface of the mould to form the component (18).
2. A method according to Claim 1 characterised by providing the layer of paint (16) on one side of a film of material (15).
3. A method according to Claim 2 characterised by causing the material of the sheet (17) to spread over the other side of the film (15) to bond therewith.
4. A method according to Claim 2 or 3 characterised by preforming the paint carrying film (15) to conform substantially with the shape of at least part (14) of the mould (10, 12) in which the component (18) is formed.
5. A method according to Claim 1 characterised by applying paint (16a) directly to the mould (10, 12) for form a layer thereon.
6. A method according to Claim 5 characterised by providing the paint as a powdered plastics paint and applying the paint to the mould by slush moulding.
7. A method according to Claim 1 characterised by providing preform means (20) corresponding substantially to the shape of at least part (14) of the mould (10, 12), providing a layer of paint (16a) on the preform means (20), removing the preformed layer of paint (16a) and positioning it in the mould (10, 12) prior to introducing the heated sheet of reinforced thermoplastics material (17).
8. A method according to Claim 7 characterised by providing the paint as a powdered plastics paint and applying the paint to the preform means (20) by slush moulding.
9. A method according to any of Claims 5 to 8 characterised by heating the sheet (17) to a temperature sufficient to cause the layer of paint (16a) and the material of the sheet (17) to bond together.
10. A method according to any preceding Claim characterised by providing a plurality of said sheets of fibre reinforced thermoplastics material (17), heating the plurality of sheets, introducing said plurality of sheets into the mould (10, 12) and compressing the sheets to cause the material of the sheets to flow over a surface of the mould and bond homogeneously together.
11. A component comprising a substrate of plastics material (17) having a coating of paint (16; 16a) to provide a finish, the component (18) being formed by providing a layer of the paint (16; 16a) in a mould (10, 12) and introducing a thermoplastics material (17) into the mould to form the substrate, the method being characterised by providing the thermoplastics material as a sheet of reinforced thermoplastics material (17), heating the sheet, introducing the heated sheet into the mould (10, 12) and compressing the sheet in the mould to cause the material of the sheet to flow over a surface of the mould to form the component (18).
12. A motor vehicle body component comprising a substrate of plastics material (17) having a coating of paint (16, 16a) to provide a finish, the component (18) being formed by providing a layer of the paint in a mould (10, 12) and introducing a thermoplastics material (17) into the mould to form the substrate, the method being characterised by providing the thermoplastics material as a sheet of reinforced thermoplastics material (17), heating the sheet, introducing the heated sheet into the mould (10, 12) and compressing the sheet in the mould to cause the material of the sheet to spread over a surface of the mould to form the component (18).
PCT/GB1992/001763 1991-09-28 1992-09-25 A method of moulding a component and a component made by such a method WO1993006981A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9402816A GB2274425B (en) 1991-09-28 1992-09-25 A method of moulding a component and a component made by such a method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB919120608A GB9120608D0 (en) 1991-09-28 1991-09-28 A method of moulding a component and a component made by such a method
GB9120608.6 1991-09-28

Publications (1)

Publication Number Publication Date
WO1993006981A1 true WO1993006981A1 (en) 1993-04-15

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WO (1) WO1993006981A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995013177A1 (en) * 1993-11-11 1995-05-18 Rover Group Limited A method of moulding and a moulding formed by such a method

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4681712A (en) * 1984-11-05 1987-07-21 Dai Nippon Toryo Co., Ltd. Molding process for plastics
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WO1988007416A1 (en) * 1987-03-27 1988-10-06 Avery International Corporation Dry paint transfer process and product
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GB2298160A (en) * 1993-11-11 1996-08-28 Rover Group A method of moulding and a moulding formed by such a method
GB2298160B (en) * 1993-11-11 1998-01-14 Rover Group A method of moulding and a moulding formed by such a method

Also Published As

Publication number Publication date
GB2274425B (en) 1995-06-21
GB9402816D0 (en) 1994-04-27
GB2274425A (en) 1994-07-27
GB9120608D0 (en) 1991-11-06

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